Environment

Sustainable development with reduced carbon footprint

Published

13 years ago

July 31, 2012

admin

The energy management, conservation and environmental aspects have been a key area in the cement and other core industries P K Ghosh, Chairman, Ercom, spells out the measures required to be taken to reduce the carbon foot print in cement industry.The Indian economy is growing at a relatively steady rate in spite of global slowdown and the demand for energy has also grown at a faster pace than what was anticipated a decade ago.To monitor the growing demand of energy with due care of the environmental aspects, the Energy Conservation Act 2001 was introduced to control the demand side management as well as ensuring the energy efficiency levels on the consumption side The Act became effective from March 2002 and Bureau of Energy Efficiency (BEE) was given the responsibility of the effective coordination and giving directions for coordination at the Centre and state level for various industries, with directives and strategies within the overall frame work of Energy Conservation ActThis is a gigantic task and increased use of our existing fuel reserves and imports of hydrocarbon products in various forms, to meet our energy supply level, creates an adverse affect on the environment during energy production and consumption The whole aspect has a vulnerable effect to the overall economy, if not done in a proper and planned manner.In this direction especially, Indian cement industry is taking a lead to evolve high technological concepts relating to energy management and conservation with special concerns on quality and environment management This has led to the various developments of alternative fuel sources, as well as technology up gradation, with the optimization of energy conservation, by adopting simple improvement methods at all levels, with the special optimization efforts on the consumption side.We all are aware about climate change and the national action plan suggested by the prime minister on 30th June, 2008, which should reduce the adverse impact of climate change and vulnerability on our system, with the projected high level of growth.India had announced on its own a reduction of CO2 emission by 20 per cent in the next 15 years, considering the year 2005 as our base line emission levels and policy measures including quality characteristic of various fuels were being made mandatory In this direction, the government has already adopted a monitoring policy needed to maintain the process on controls as per KYOTO Protocol Even during 2010 summit, our Ministry for Environment and Forest had made a statement to this effect.The Ministry of Power and the Bureau of Energy Efficiency (BEE) are responsible for the implementation of the National Mission for Enhanced Energy Efficiency (NMEEE) The BEE and other related agencies are monitoring the implementation of NMEEE and PAT (Perform, Achieve and Trade) PAT is a market based mechanism to make efficiency improvements in energy intensive large industries as well as making facilities more cost-effective by providing Energy Saving Certificates (ESCerts) that can be traded.The Ministry of Power had identified nine industrial sectors that will be under the PAT scheme, namely thermal power plant, fertilizer, cement, pulp and paper, textile, chlor-alkali, iron and steel, aluminum and railways.The PAT scheme for cement Industry includes the typical energy distribution process in the cement plant boundary and the SEC is then worked out as follows:

The plant will have a total input energy.
The plant may have captive power plant for self consumption and consuming coal with certain GCV.
Plant may be receiving power from Grid.
Coal used for clinker production and raw material – drying.
HFO / other fuel used for kiln light up and emergency drive.
Total output at plant box / boundary converted into equivalent cement.
Specific energy consumption worked out based on total cement production basis.

PAT scheme thus introduced will definitely bring down the carbon footprint and there would be saving of fuel and energy level but for our targeted growth, more power plant / additional energy sources would be needed, which can be partially met from renewable energy sources as well as waste heat recovery sources, under the PAT schemeThe specific energy consumption data for last three years were to be submitted by all cement companies last year (March 2011) Based on the same, every cement company will have to optimize / reduce the specific energy consumption, from its base figure to a targeted figure in the next three years (2013-14) If any company is achieving SEC – saving more than the targeted figure, then they would be entitled for ESCerts, which eventually can be traded through an agency by following the approved modus operandi In case any company fails to reach the given target, then the company will have to comply by purchasing the ESCerts and continue to work to achieve the set targets.To achieve the target levels, first task in hand should be to improve the energy efficiency levels and this basically comes from the productivity related approach and energy saving concepts, which aims at efficient O&M and overall economies of scale.To facilitate the implementation of PAT scheme for the consumers, the Energy Conservation Act, was modified / amended suitably in 2010 (EC Amendment Act) The designated consumers are likely to get the ESCert from the Central government, including purchase of the Certificate to comply with the prescribed norms and standards The Central government may fix in consultation with BEE/NMEE the value of per MT of pozzolanic material including slag for different blending applications, as per the prescribed standards This will reduce the specific energy consumption per tonne considerably.The mission and objective to ensure a sustainable growth will basically be from the 3-4 factors namely the environment, plant efficiency levels, energy conservation and equity etc., to be achieved against the specific targets for mandatory energy saving.The ordinary portland cement which does not include any additive as such except 3-4 per cent of gypsum, consumes the maximum energy per tonne and manufacture of blended cement reduces the specific power consumption per tonne and hence the use of green technologies as well as nanotechnologies to bring down carbon foot-print can be derived from the followings:

Renewable / solar energy
Waste heat recovery system (WHR)
Wind mills,
Green cement and related products made out of ground slag and class F&C flyash with certain additives and activators, where direct use of clinker / cement can be avoided and this can reduce the carbon foot print considerably.

The government should encourage nano/green technologies more and more in the best interest of mineral conservation, which can increase the utilization of fly ash/slag/alternate fuels/renewable energies etc., which would reduce the ultimate emission levels as well as carbon foot printTo implement this, there are several measures which need to be considered in a planned manner to make the community life also sustainable along with inclusive and sustainable growth In this direction, biomass fuels, agro-wastes, etc are being used in a big way as alternative fuel to reduce carbon foot print.Similarly, by using blended cement, specially with green technologies/nano-technologies involved, the durability and strength of concrete roads with their distinct advantages over bitumen surfaces, should definitely be tried for the rural roads/high ways and test cases can be allowed under strict concrete specifications and close monitoring, to establish it in the next 1 or 2 years, due to the tremendous scope for enhancing the durability and strength through the concretization.The green technologies involved in such applications, can be tested and cleared as per the local BIS standards and may be considered under category of masonry cement / composite cement, for the low cost housing, low intensity structures, lining of canals / river side embedment, concrete bricks, tiles, pavements, fly ash aggregates, light weight aggregates etc., by this not only carbon foot prints can be controlled and reduced, but the environment and our mineable reserves of various useful rare minerals, can also be preserved for a long time, for our inclusive and sustainable growth.

Concrete

India donates 225t of cement for Myanmar earthquake relief

Published

6 days ago

June 17, 2025

admin

On 23 May 2025, the Indian Navy ship UMS Myitkyina arrived at Thilawa (MITT) port carrying 225 tonnes of cement provided by the Indian government to aid post-earthquake rebuilding efforts in Myanmar. As reported by the Global Light of Myanmar, a formal handover of 4500 50kg cement bags took place that afternoon. The Yangon Region authorities managed the loading of the cement onto trucks for distribution to the earthquake-affected zones.

Concrete

Reclamation of Used Oil for a Greener Future

Published

7 days ago

June 16, 2025

admin

In this insightful article, KB Mathur, Founder and Director, Global Technical Services, explores how reclaiming used lubricants through advanced filtration and on-site testing can drive cost savings, enhance productivity, and support a greener industrial future. Read on to discover how oil regeneration is revolutionising sustainability in cement and core industries.

The core principle of the circular economy is to redefine the life cycle of materials and products. Unlike traditional linear models where waste from industrial production is dumped/discarded into the environment causing immense harm to the environment;the circular model seeks to keep materials literally in continuous circulation. This is achievedthrough processes cycle of reduction, regeneration, validating (testing) and reuse. Product once
validated as fit, this model ensures that products and materials are reintroduced into the production system, minimising waste. The result? Cleaner and greener manufacturing that fosters a more sustainable planet for future generations.

The current landscape of lubricants
Modern lubricants, typically derived from refined hydrocarbons, made from highly refined petroleum base stocks from crude oil. These play a critical role in maintaining the performance of machinery by reducing friction, enabling smooth operation, preventing damage and wear. However, most of these lubricants; derived from finite petroleum resources pose an environmental challenge once used and disposed of. As industries become increasingly conscious of their environmental impact, the paramount importance or focus is shifting towards reducing the carbon footprint and maximising the lifespan of lubricants; not just for environmental reasons but also to optimise operational costs.
During operations, lubricants often lose their efficacy and performance due to contamination and depletion of additives. When these oils reach their rejection limits (as they will now offer poor or bad lubrication) determined through laboratory testing, they are typically discarded contributing to environmental contamination and pollution.
But here lies an opportunity: Used lubricants can be regenerated and recharged, restoring them to their original performance level. This not only mitigates environmental pollution but also supports a circular economy by reducing waste and conserving resources.

Circular economy in lubricants
In the world of industrial machinery, lubricating oils while essential; are often misunderstood in terms of their life cycle. When oils are used in machinery, they don’t simply ‘DIE’. Instead, they become contaminated with moisture (water) and solid contaminants like dust, dirt, and wear debris. These contaminants degrade the oil’s effectiveness but do not render it completely unusable. Used lubricants can be regenerated via advanced filtration processes/systems and recharged with the use of performance enhancing additives hence restoring them. These oils are brought back to ‘As-New’ levels. This new fresher lubricating oil is formulated to carry out its specific job providing heightened lubrication and reliable performance of the assets with a view of improved machine condition. Hence, contributing to not just cost savings but leading to magnified productivity, and diminished environmental stress.

Save oil, save environment
At Global Technical Services (GTS), we specialise in the regeneration of hydraulic oils and gear oils used in plant operations. While we don’t recommend the regeneration of engine oils due to the complexity of contaminants and additives, our process ensures the continued utility of oils in other applications, offering both cost-saving and environmental benefits.

Regeneration process
Our regeneration plant employs state-of-the-art advanced contamination removal systems including fine and depth filters designed to remove dirt, wear particles, sludge, varnish, and water. Once contaminants are removed, the oil undergoes comprehensive testing to assess its physico-chemical properties and contamination levels. The test results indicate the status of the regenerated oil as compared to the fresh oil.
Depending upon the status the oil is further supplemented with high performance additives to bring it back to the desired specifications, under the guidance of an experienced lubrication technologist.
Contamination Removal ? Testing ? Additive Addition
(to be determined after testing in oil test laboratory)

The steps involved in this process are as follows:
1. Contamination removal: Using advanced filtration techniques to remove contaminants.
2. Testing: Assessing the oil’s properties to determine if it meets the required performance standards.
3. Additive addition: Based on testing results, performance-enhancing additives are added to restore the oil’s original characteristics.

On-site oil testing laboratories
The used oil from the machine passes through 5th generation fine filtration to be reclaimed as ‘New Oil’ and fit to use as per stringent industry standards.
To effectively implement circular economy principles in oil reclamation from used oil, establishing an on-site oil testing laboratory is crucial at any large plants or sites. Scientific testing methods ensure that regenerated oil meets the specifications required for optimal machine performance, making it suitable for reuse as ‘New Oil’ (within specified tolerances). Hence, it can be reused safely by reintroducing it in the machines.
The key parameters to be tested for regenerated hydraulic, gear and transmission oils (except Engine oils) include both physical and chemical characteristics of the lubricant:

Kinematic Viscosity
Flash Point
Total Acid Number
Moisture / Water Content
Oil Cleanliness
Elemental Analysis (Particulates, Additives and Contaminants)
Insoluble

The presence of an on-site laboratory is essential for making quick decisions; ensuring that test reports are available within 36 to 48 hours and this prevents potential mechanical issues/ failures from arising due to poor lubrication. This symbiotic and cyclic process helps not only reduce waste and conserve oil, but also contributes in achieving cost savings and playing a big role in green economy.

Conclusion
The future of industrial operations depends on sustainability, and reclaiming used lubricating oils plays a critical role in this transformation. Through 5th Generation Filtration processes, lubricants can be regenerated and restored to their original levels, contributing to both environmental preservation and economic efficiency.
What would happen if we didn’t recycle our lubricants? Let’s review the quadruple impacts as mentioned below:
1. Oil Conservation and Environmental Impact: Used lubricating oils after usage are normally burnt or sold to a vendor which can be misused leading to pollution. Regenerating oils rather than discarding prevents unnecessary waste and reduces the environmental footprint of the industry. It helps save invaluable resources, aligning with the principles of sustainability and the circular economy. All lubricating oils (except engine oils) can be regenerated and brought to the level of ‘As New Oils’.
2. Cost Reduction Impact: By extending the life of lubricants, industries can significantly cut down on operating costs associated with frequent oil changes, leading to considerable savings over time. Lubricating oils are expensive and saving of lubricants by the process of regeneration will overall be a game changer and highly economical to the core industries.
3. Timely Decisions Impact: Having an oil testing laboratory at site is of prime importance for getting test reports within 36 to 48 hours enabling quick decisions in critical matters that may
lead to complete shutdown of the invaluable asset/equipment.
4. Green Economy Impact: Oil Regeneration is a fundamental part of the green economy. Supporting industries in their efforts to reduce waste, conserve resources, and minimise pollution is ‘The Need of Our Times’.

About the author:
KB Mathur, Founder & Director, Global Technical Services, is a seasoned mechanical engineer with 56 years of experience in India’s oil industry and industrial reliability. He pioneered ‘Total Lubrication Management’ and has been serving the mining and cement sectors since 1999.

Concrete

Charting the Green Path

Published

1 month ago

May 13, 2025

admin

The Indian cement industry has reached a critical juncture in its sustainability journey. In a landmark move, the Ministry of Environment, Forest and Climate Change has, for the first time, announced greenhouse gas (GHG) emission intensity reduction targets for 282 entities, including 186 cement plants, under the Carbon Credit Trading Scheme, 2023. These targets, to be enforced starting FY2025-26, are aligned with India’s overarching ambition of achieving net zero emissions by 2070.
Cement manufacturing is intrinsically carbon-intensive, contributing to around 7 per cent of global GHG emissions, or approximately 3.8 billion tonnes annually. In India, the sector is responsible for 6 per cent of total emissions, underscoring its critical role in national climate mitigation strategies. This regulatory push, though long overdue, marks a significant shift towards accountability and structured decarbonisation.
However, the path to a greener cement sector is fraught with challenges—economic viability, regulatory ambiguity, and technical limitations continue to hinder the widespread adoption of sustainable alternatives. A major gap lies in the lack of a clear, India-specific definition for ‘green cement’, which is essential to establish standards and drive industry-wide transformation.
Despite these hurdles, the industry holds immense potential to emerge as a climate champion. Studies estimate that through targeted decarbonisation strategies—ranging from clinker substitution and alternative fuels to carbon capture and innovative product development—the sector could reduce emissions by 400 to 500 million metric tonnes by 2030.
Collaborations between key stakeholders and industry-wide awareness initiatives (such as Earth Day) are already fostering momentum. The responsibility now lies with producers, regulators and technology providers to fast-track innovation and investment.
The time to act is now. A sustainable cement industry is not only possible—it is imperative.